Apparatus for securing a trim cover with a foam pad and method of using the same

ABSTRACT

An apparatus for securing a trim cover to a foam pad includes a base and a platform coupled thereto that defines a working surface for supporting the foam pad thereon. A plurality of actuators project from the working surface. Each actuator is capable of movement away from and toward the working surface and includes a pair of retaining fingers capable of movement between an open and closed position. In use, the retaining fingers grasp a first connecting member on the trim cover and move the first connecting member toward the working surface as the actuators are moved toward the working surface so as to engage the first connecting member with a second connecting member in the foam pad thereby securing the trim cover to the foam pad.

CROSS-REFERENCE

This application is a divisional application of U.S. patent applicationSer. No. 11/161,149 filed Jul. 25, 2005, now issued as U.S. Pat. No.7,430,793, the disclosure of which is incorporated by reference hereinin its entirety.

FIELD OF THE INVENTION

The present invention pertains generally to an apparatus for making aseat cushion, and more particularly to an apparatus for securing a trimcover to a foam pad of the type utilized for seating and back cushionson automotive seats.

BACKGROUND OF THE INVENTION

Many surfaces within a passenger compartment of a motor vehicle requirepadding for comfort reasons. For instance, an automotive vehicleincludes seat assemblies for supporting occupants within the vehicleabove the floorpan. Typically, a seat assembly includes a seat cushionand a seat back each comprising a foam pad. Aesthetically, materialsused to make the foam pads lack the desired finish and durability.Therefore, trim covers are employed to cover the foam padding so thelook, feel and durability of the padded seat cushion meets the demandsand expectations of car manufacturers and consumers.

Trim covers are attached to the foam pad of seat cushions in a varietyof ways. Some of the most common ways include the use of hook and loopfasteners, adhesives, hog rings, drawstrings and other devices andmethods. An example of such a method is shown in U.S. Pat. No. 4,692,199which discloses a particularly well-adapted method of making a fabriccovered foam article. The patent specifically discloses a method whereinvacuum pressure is applied to a porous contoured mold in order to drawan impervious adhesive film against a cloth fabric layer to conform thecloth fabric layer to the contours of the mold surface. A matchingcellular foam pad is placed in mating engagement with the adhesive filmas it is held to the contour of a mold surface by the vacuum pressure.The foam pad is compressed against the mold by a perforated platen andheld in place as the vacuum pressure is discontinued. Steam is thensupplied through the porous mold to heat and diffuse the adhesive filminto the adjacent fabric layer and cellular foam pad for adhesivelysecuring the two together. Vacuum pressure is then applied for removingmoisture by drawing air through the perforations of the platen, the foampad, the fabric layer and porous mold.

Another method of securing a trim cover to a piece of molded foam, suchas in a seat cushion, is to mold fasteners into the foam pad as it ismolded and cured. In this securing method, a fastener, such as one of ahook or loop fastener extends along a portion of the foam pad surface.For instance, the fasteners may be placed in a trench between differentcontoured surfaces of the foam pad. A complementary fastener, i.e., theother of the hook or loop fastener, extends along the inner surface ofthe trim cover. The trim cover is then placed around the foam pad sothat the fasteners engage one another and thereby secure the trim coverwith the foam pad. To this end, an operator may take a blunt edged tool,such as a putty knife, and push the trim cover into the trench in thefoam pad so as to pull the trim cover tight over the foam pad and toengage the fasteners.

These methods, however, have some drawbacks. In particular, thesemethods are expensive and/or labor intensive. In some of these methods,significant equipment and other tooling requirements are needed topractice the process. In other methods, much of the process is donemanually. For example, the hook and loop fastening system as describedabove typically is achieved through a manual process. Manual processingsteps not only increases the labor costs associated with the seatassembly but also limit the production rate.

There is thus a need for an apparatus for securing a trim cover with afoam pad and a method of using the same that overcomes these and otherdisadvantages and shortcomings of present devices and methods.

SUMMARY OF THE INVENTION

The present invention provides an improved apparatus for securing a trimcover to a foam pad. The apparatus includes a base and a platformcoupled to the base that defines a working surface for supporting thefoam pad thereon. A plurality of actuators project from the workingsurface and are adapted to extend through apertures in the foam pad.Each of the actuators is capable of movement away from and toward theworking surface and include a pair of retaining fingers on one endthereof which are capable of movement between an open position and aclosed position. The retaining fingers are adapted to grasp a firstconnecting member on the trim cover and move the first connecting membertoward the working surface as the actuators are moved toward the workingsurface so as to engage the first connecting member with a secondconnecting member on the foam pad to secure the trim cover with the foampad.

In an exemplary embodiment of the invention, the platform is pivotallycoupled with the base so that the angle the platform makes with the basemay be selectively changed and thereby provide a more ergonomicapparatus. Additionally, the actuators may be linear actuators that movein a direction substantially perpendicular to the working surface. Theactuators may be driven in any suitable manner as is known in the artbut are preferably pneumatic actuators. To control the movement of theactuators and the retaining fingers, the apparatus may include acontroller. The controller may include one or more switches, such as abanner switch, foot pedal or other hand or finger switches known in theart, for moving the actuators and/or retaining fingers. For instance,activation of a switch may open and close the retaining fingers.Likewise, activation of the switch may move the actuators away from andtoward the working surface. Alternately, the movement of the actuatorsand/or retaining fingers may be automated by, for example, programmingthe controller to move the actuators and retaining fingers in a timedsequence.

The exemplary embodiment of the invention may also include a pluralityof supports projecting from the working surface. The supports areadapted to support the second connecting member in the foam pad duringengagement of the first connecting member with the second connectingmember. Because the foam pad is deformable, the supports limit themovement of the second connecting members during the securing process.The supports may be adjustable so as to selectively change the height ofthe support with respect to the working surface. Moreover, each of thesupports may be positioned adjacent an associated actuator.

A method of using the apparatus includes placing the trim cover over thefoam pad so that the first connecting member on the trim cover alignswith the second connecting member in the foam pad and then moving theactuators to couple the first connecting member with the secondconnecting member. To this end, the actuators are moved in a firstdirection, such as away from the working surface. The retaining fingersare then moved to a closed position so as to grasp the first connectingmember on the trim cover thereby engaging the first connecting memberwith the actuators. The actuators are then moved in a second direction,such as toward the working surface, so as to engage the first connectingmember with the second connecting member in the foam pad. The retainingfingers on the actuators are then moved to an open position so as torelease the first connecting member from the actuators.

The features and objectives of the present invention will become morereadily apparent from the following Detailed Description taken inconjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate embodiments of the invention and,together with a general description of the invention given above, andthe detailed description given below, serve to explain certainembodiments of the invention.

FIG. 1 is a perspective view of an apparatus in accordance with theinvention;

FIG. 2 is a partial cross-sectional view of the apparatus of FIG. 1 withthe trim cover overlying the foam pad and the actuators grasping thefirst connecting member;

FIG. 2A is a partial cross-sectional view of FIG. 2 generally along line2A-2A;

FIG. 2B is a partial cross-sectional view of FIG. 2 generally along line2B-2B;

FIG. 3 is a partial cross-sectional view of the apparatus of FIG. 1 withthe trim cover secured with the foam pad;

FIG. 3A is a partial cross-sectional view of FIG. 3 generally along line3A-3A; and

FIG. 3B is a partial cross-sectional view of FIG. 3 generally along line3B-3B.

DETAILED DESCRIPTION OF THE DRAWINGS

With reference to FIG. 1, an apparatus 10 for securing a trim cover 12with a foam pad 14, such as for an automotive seat or back cushion orany other padded interior component of a vehicle, includes a base 16having a plurality of legs 18 adapted to engage the ground 20, such asthe floor of an automotive factory, at a bottom end thereof. It will beappreciated that base 16 may take any other desired form including onethat does not include legs for engaging the floor but instead is atabletop unit. A generally planar platform 22 is coupled to an upper endof the base 16 and defines a working surface 24 which supports the foampad 14. The base 16 and platform 22 may be made from any suitablestructural material, such as steel, aluminum, wood, rigid plastic andother materials as recognized by those of ordinary skill in the art. Thebase 16 and platform 22 may be made from the same material or be madefrom different materials as desired.

To make the apparatus 10 more ergonomic, the platform 22 is pivotallycoupled with the base 16 so that the angle the platform 22 makes withbase 16 may be selectively changed to accommodate different sizedoperators (not shown) and provide more comfortable operating conditions.For instance, the platform 22 may include an actuator (not shown), suchas a pneumatic cylinder, to pivot the platform 22 and to hold theplatform 22 at a fixed angle with respect to base 16. In a similarmanner, the legs 18 may also be adjustable so as to selectively changethe height of the platform 22 with respect to the ground 20. Those ofordinary skill in the art will recognize other ways to change the anglethe platform 22 makes with the base 16 or the height of platform 22.

The apparatus 10 further includes a plurality of actuators 32 thatproject from the working surface 24. The actuators 32 may be arranged asdesired so as to accommodate a specific application. For instance, asshown in FIG. 1, the actuators 32 may be arranged in two rowscorresponding to seams between contoured portions of the foam pad 14, asdiscussed in more detail below. In an advantageous aspect of theinvention, the actuators 32 are capable of movement toward and away fromthe working surface 24. Those of ordinary skill in the art willrecognize that a wide variety of actuators may be used in the invention.In an exemplary embodiment, however, the actuators 32 may be linearactuators that move in a direction substantially perpendicular toworking surface 24. Moreover, the actuators 32 may be operated in anysuitable manner, but preferably are pneumatic actuators that may becoupled with a pressurized air supply 34.

Each of the actuators 32 includes a pair of retaining fingers 36positioned at an end of the actuator 32 which are movable between anopen position and a closed position. In the open position, the retainingfingers 36 are adapted to receive an object, such as a connectingmember, therebetween. In the closed position, the retaining fingers 36are adapted to grasp and secure the object to the actuators 32. Asrecognized by those of ordinary skill in the art, the retaining fingers36 may be operated in a wide variety of ways, but preferably arepneumatically operated. Thus, for example, when air pressure is applied,the retaining fingers 36 are in an open position and when the airpressure is released, the retaining fingers 36 are in a closed position.To this end, the retaining fingers 36 may also be coupled to air supply34.

The apparatus 10 may further include a controller, generally shown at38, for controlling the movement of the actuators 32 and the retainingfingers 36. It should be recognized that while the preferred embodimentshows controlling the actuators 32 and retaining fingers 36 with thesame controller 38, multiple controllers may be used in the invention.Moreover, in one embodiment, the apparatus 10 includes a switch 40coupled with controller 38 which may be manually activated, such as byan operator, to move the actuators 32 and the retaining fingers 36. Byway of example, switch 40 may include a foot pedal, hand switch, fingerswitch or other switches known in the art such that activation of theswitch 40 moves the actuators 32 away from and toward working surface24. In a similar manner, activation of switch 40 may also move theretaining fingers 36 between the open and closed positions. Again, itshould be recognized that while one switch 40 is shown for activatingthe actuators 32 and retaining fingers 36, multiple switches may be usedin the invention. In an alternate embodiment of the invention, themovement of the actuators 32 and retaining fingers 36 may be automated,such as by programming the controller 38 to move the actuators 32 andretaining fingers 36 in a timed sequence.

The apparatus 10 may further include a plurality of supports 42projecting from working surface 24 and, as explained in more detailbelow, are adapted to support a connecting member in foam pad 14 duringsecurement of the trim cover 12 with foam pad 14. The supports 42 may beadjustable so as to selectively change the height of supports 42relative to the working surface 24. In one embodiment, the supports 42include a mushroom shaped head 44 coupled with an end of threaded rod46. The rod 46 is inserted through a bore 48 in platform 22. A firststop 50 may be coupled with the threaded rod 46 and positioned adjacentthe working surface 24. For instance, the first stop 50 may be asuitable washer and nut. A second stop 52 may also be coupled with thethread rod 46 and positioned adjacent a back surface 54 of platform 22.The second stop 52 may also be a suitable washer and nut. By movingfirst and second stops 50, 52, the height of the supports 42 withrespect to the working surface 24 may be changed. As with the actuators32, the supports 42 may be arranged as desired so as to accommodate aspecific application. For instance, as shown in FIG. 1, the supports 42may be arranged in two rows and located adjacent an associated actuator32.

The apparatus 10 as described above is adapted to be used to secure thetrim cover 12 with the foam pad 14. To this end, the trim cover 12includes a first connecting member 56 and the foam pad 14 includes asecond connecting member 58 wherein when the first and second connectingmembers 56, 58 are engaged, the trim cover 12 is secured to the foam pad14. Bottom seat and back cushions in many automotive seat assemblies areoften times contoured, i.e., including multiple portions with differentshapes. The various contours in a seat cushion may be formed bycorresponding contours in the foam pad 14. For illustrative purposes,the foam pad 14 shown in FIGS. 2A and 3A includes a first portion 60that is generally planar and an adjoining second portion 62 on one edgeof first portion 60 that has a generally arcuate shape. Another portionsimilar to second portion 62 may be located on an opposed edge of firstportion 60, such as shown in FIG. 1. Collectively, the first and secondportions 60, 62 give the seat cushion a contoured aspect, which adds tothe overall aesthetic appeal of the seat assembly and automotiveinterior.

To facilitate covering the foam pad 14 with trim cover 12, foam pad 14includes a trench 64 along the edge between the first and secondportions 60, 62. The trim cover 12 couples with the foam pad 14 alongtrench 64 so as to form a seam between the two portions 60, 62 (as seenfrom a top view of the cushion) when the trim cover 12 is secured withthe foam pad 14. To this end, the foam pad 14 includes second connectingmember 58. Second connecting member 58 may generally include one or moremembers adapted to cooperate with another member(s) to secure an objectto the foam pad 14. In an exemplary embodiment, and as shown in FIGS. 2,2A, 3 and 3A, the second connecting member 58 may include a plurality ofclips 66 spaced along trench 64. As best shown in FIGS. 2A and 3A, theclips 66 may include a generally circular base 68 and a pair of spacedapart arms 70 projecting therefrom. Each arm 70 includes a projection 72on confronting inner surfaces. The arms 70 on clips 66 are adapted toelastically deform outwardly so as to receive the first connectingmember 56 therein. The clips 66 may be coupled with the foam pad 14during the manufacturing of foam pad 14. For instance, foam pad 14 maybe formed through an injection molding process wherein the clips 66 arepositioned in the mold (not shown) prior to injection and uponsubsequent injection and curing of the foam material, the base 68 ofeach clip 66 is encased within the foam pad 14 while the arms 70 arepositioned within the trench 64, as shown in these figures.

A foam pad 14 particularly adapted to be used with apparatus 10 alsoincludes a plurality of apertures 74 extending completely through thefoam pad 14 and along trench 64. The apertures 74 are adapted to receivean associated actuator 32 therein when the foam pad 14 is placed on theworking surface 24. Preferably, the apertures 74 are positioned adjacentto the clips 66 so that when the foam pad 14 is placed on workingsurface 24, there is an actuator 32 associated with each clip 66 (FIG.1). In addition, foam pad 14 includes a plurality of blind bores 76formed therein that register with clips 66. The bores 76 stop short ofclips 66 and are adapted to receive an associated support 42 therein. Inthis way, when the foam pad 14 is placed on the working surface 24, thehead 44 of support 42 is just below the base 68 of clip 66. Thisconfiguration limits movement of the clip 66 toward the working surface24.

The trim cover 12 used to cover foam pad 14 may be any suitableaesthetically pleasing material such as cloth, leather, vinyl, etc. Tofacilitate securing the trim cover 12 with the foam pad 14, the trimcover 12 includes a first connecting member 56. First connecting member56 may generally include one or more members adapted to cooperate withanother member(s) to secure an object to the trim cover 12. As shown inFIGS. 1-3B, the first connecting member 56 may include a connectingstrip 78. As best shown in FIGS. 2A-3B, connecting strip 78 includes anarrow shaped head 80 coupled at one end of an extending tab 82 havingfirst and second opposed sides 84, 86. Trim cover 12 includes aplurality of portions corresponding to the contoured portions in foampad 14. Thus, trim cover 12 includes a first portion 88 adapted tooverlie and cover first portion 60 in foam pad 14 and a second portion90 adapted to overlie and cover second portion 62 in foam pad 14.Adjacent ends of first and second portions 88, 90 in trim cover 12 arecoupled to sides 84, 86 of extending tab 82. This may be accomplished,for example, by sewing the ends of first and second portions 88, 90 withextending tab 82. Those of ordinary skill in the art will recognizeother methods for coupling the trim cover 12 with the connecting strip78.

A method of using apparatus 10 to secure trim cover 12 with foam pad 14will now be described. An operator typically places the foam pad 14 ontothe working surface 24 of apparatus 10. The foam pad 14 is placed onworking surface 24 such that the actuators 32 extend through apertures74 in foam pad 14 and the supports 42 are located in blind bores 76 soas to support the second connecting member 58, such as clips 66 embeddedwithin the foam pad 14. Those of ordinary skill in the art willrecognize that the foam pad 14 may be placed on working surface 24 andthen actuators 32 moved away from working surface 24 so as to completelyextend through apertures 74 in foam pad 14. The trim cover 12 carryingthe first connecting member 56, such as connecting strip 78, ispositioned to overlie the foam pad 14 and the connecting strip 78 isaligned with the clips 66 in the foam pad 14. The retaining fingers 36are moved to an open position so as to receive the arrow-shaped head 80therebetween.

The retaining fingers 36 are then moved to a closed position so as tograsp the arrow-shaped head 80 on connecting strip 78. The actuators 32are then moved toward the working surface 24 so that the arrow-shapedhead 80 engages the arms 70 on clips 66 and deforms them outwardly asthe actuators 32 move toward working surface 24. As the head 80 engagesthe arms 70, the supports 42 prevent movement of the clips 66 towardworking surface 24 thus causing relative motion between the first andsecond connecting members 56, 68. When the arrow-shaped head 80 clearsthe projection 72 on arms 70, the arms 70 snap inwardly so as to couplethe connecting strip 78 with the clips 66 thereby securing the trimcover 12 with the foam pad 14. The movement of the actuators 32 towardthe working surface 24 is stopped and the retaining fingers 36 are movedto the open position so as to release the connecting strip 78 therefrom.The operator may then remove the coupled trim cover 12 and foam pad 14from the apparatus 10. The process may then be repeated to formadditional seat cushions.

As described above, the movement of the actuators 32 away from andtoward the working surface 24 and movement of the retaining fingers 36between the open and closed positions may be accomplished by activatingswitch 40. Thus for example, repeated activation of switch 40 mayrespectively cause: i) the actuators 32 to move away from workingsurface 24; ii) the retaining fingers 36 to move to a closed position;iii) the actuators 32 to move toward the working surface 24; and iv) theretaining fingers 36 to move to an open position. The controller 38 mayalso be programmed to perform these steps in a timed sequence.

While the present invention has been illustrated by the description ofthe various embodiments thereof, and while the embodiments have beendescribed in considerable detail, it is not intended to restrict or inany way limit the scope of the appended claims to such detail.Additional advantages and modifications will readily appear to thoseskilled in the art. The invention in its broader aspects is thereforenot limited to the specific details, representative apparatus andmethods and illustrative examples shown and described. Accordingly,departures may be made from such details without departing from thescope or spirit of the general inventive concept.

1. A method of securing a trim cover to a foam pad, comprising:positioning the foam pad on a working surface; positioning the trimcover relative to the foam pad so that a first connecting member coupledto the trim cover aligns with a second connecting member coupled to thefoam pad; supporting the second connecting member with a support coupledto the working surface to limit the movement of the second connectingmember in at least one direction, the foam pad being positioned on theworking surface so that the support coupled to the working surface ispositioned in a blind bore in the foam pad that is adjacent the secondconnecting member; securing the first connecting member to a movableactuator; and moving the actuator to couple the first connecting memberwith the second connecting member and thereby secure the trim cover tothe foam pad.
 2. The method of claim 1, further comprising: positioningthe foam pad on the working surface so that the actuator aligns with abore formed through the foam pad.
 3. The method of claim 2, furthercomprising: moving the actuator through the bore in the foam pad tosecure the first connecting member to the actuator.
 4. The method ofclaim 1, wherein securing the first connecting member to the actuatorcomprises: moving a pair of retaining fingers on the actuator to aclosed position to capture the first connecting member to the actuator.5. The method of claim 1, further comprising: releasing the firstconnecting member from the actuator after the first and secondconnecting members are coupled.
 6. The method of claim 5, whereinreleasing the first connecting member from the actuator comprises:moving a pair of retaining fingers on the actuator to an open positionto release the first connecting member from the actuator.
 7. The methodof claim 1, further comprising: adjusting the height of the support tolimit movement of the second connecting member.
 8. A method of securinga trim cover to a foam pad, comprising: positioning the foam pad on aworking surface so that a movable actuator aligns with a bore formedthrough the foam pad; positioning the trim cover relative to the foampad so that a first connecting member coupled to the trim cover alignswith a second connecting member coupled to the foam pad; moving theactuator in a first direction away from the working surface and throughthe bore in the foam pad; securing the first connecting member to theactuator by moving a pair of retaining fingers on the actuator to aclosed position to capture the first connecting member to the actuator;moving the actuator in a second direction toward the working surface;supporting the second connecting member with a support coupled to theworking surface to limit the movement of the second connecting member inthe second direction, the foam pad being positioned on the workingsurface so that the support coupled to the working surface is positionedin a blind bore in the foam pad that is adjacent the second connectingmember; coupling the first connecting member to the second connectingmember; and releasing the first connecting member from the actuator bymoving the pair of retaining fingers to an open position.
 9. A method ofsecuring a trim cover having a first connecting member to a foam padhaving a second connecting member using a movable actuator, the methodcomprising: positioning the foam pad on a working surface; positioningthe trim cover relative to the foam pad so that the first connectingmember aligns with the second connecting member; and moving the actuatorto couple the first connecting member with the second connecting memberand thereby secure the trim cover to the foam pad, wherein moving theactuator to couple the first connecting member with the secondconnecting member further comprises: (i) moving the actuator in a firstdirection; (ii) engaging the first connecting member with the actuator;(iii) supporting the second connecting member with a support coupled tothe working surface to limit the movement of the second connectingmember in a second direction, the foam pad being positioned on theworking surface so that the support coupled to the working surface ispositioned in a blind bore in the foam pad that is adjacent the secondconnecting member; (iv) moving the actuator in the second direction toengage the first connecting member with the second connecting member;and (v) releasing the first connecting member from the actuator.
 10. Themethod of claim 9, wherein steps (i), (ii), (iv), and (v) are executedin a timed sequence.
 11. The method of claim 9, further comprising:activating a switch prior to each of steps (i), (ii), (iv), and (v). 12.The method of claim 9, wherein engaging the first connecting member withthe actuator includes closing a pair of retaining fingers to capture thefirst connecting member to the actuator.
 13. The method of claim 9,wherein releasing the first connecting member from the actuator includesopening a pair of retaining fingers to release the first connectingmember from the actuator.
 14. The method of claim 9, wherein moving theactuator in a first direction includes moving the actuator through abore formed in the foam pad.